Turbocharger Overhaul Instruction

Garrett TBP4
Before you read this instruction, I have to say sorry my English is not that good to describe it
well about how to rebuild turbocharger. If there is anything wrong, any better words or suggestion
for this instruction, just email me to Kansai_sport@hotmail.com

The T3/T4 rebuild kit you purchased from Kansai-sport is new and complete dynamic kit for T3
/ T4 / T04B / T04E / TBP4…

Eiji Takada in Osaka, Japan.

2007/12/22

Now let’s see how to take apart of Garrett TBP4 turbo and change rebuild kit.

Please remove the bolts between bearing housing and compressor housing and turbine
housing.
 Sometimes it is hard to swap bearing housing and turbine housing as there is much
carbon. I will use acetylene to heart it and then we can swap it easily.

If you can take apart it easily, of course, you can leave this step.

Now we take apart the bearing system and turbine housing

 Let us take apart of compressor housing and cartridge.

Please remove the bolt.

Be care! When you remove compressor housing, don’t harm the same point of edge, it may
damage the compressor wheel. Please remove the housing by harming different edge of
compressor housing after you remove the bolts.
Before you take apart of CHRA, please make sure to scribe a line across the compressor wheel,
nut, and the end of the shaft at this time. If you do not bolt it back together with ALL of the lines
lined up, your turbo may end up being out of balance, and it can quickly destroy itself.

Place the turbine blade "nut" in a vice, and either use a T-handle socket to remove the
compressor blade nut, or when using the ratchet, make sure to hold the socket so that the
ratchet is only twisting the nut, not placing any side load on the center shaft. Evidently it is
easy to bend the center shaft if you place too much of a side load on it when removing the
nut. When I removed the one in the picture, I was very careful to grab the ratchet at the
rotating end and put all the twisting force directly through the socket, without putting any
side load on the shaft.

Be VERY careful of the wheels, the blades can really tear your hands up. It is safest to
wrap them in towels, because if the nut breaks free and your hands hit either wheel, you
could be seeing a lot of blood.
 Remove the turbine wheel and then you can take off the journal bearing and heat shield

Please remove piston ring (Seal Ring) on turbine shaft and clean the carbon on shaft groove
and shaft. Remove the used piston ring and Polish up the shaft using 1200 grit sand paper to
remove surface varnish then polish it with some kind of metal polish. For best operation the turbo
shaft should shine with no scoring marks or dull spots. Rinse the shaft and exhaust wheel
assembly under petroleum ether to get rid of all the polish
 Remove the bolts knocks the plate and bearing housing

We will see the thrust collar with piston ring (seal) and thrust bearing kit. You can use the stock
collar with new thrust bearing kit as well.
 Thrust collar and thrust bearing

Collar with piston ring (seal)

Now we will remove the c-clip on both size to get old journal bearing.
 Here is an o-ring we have to change as well.

Now we finish take apart all the bearing kit.

Most of old turbos are dirty like this picture, please remove the carbon and dirty stuff as you can.
If you wanna sandblast the bearing housing, please remember not to sand the central connects
to journal bearing.
 It is the turbine wheel / shaft with new piston ring

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Now let’s install new turbo rebuild kit step by step.

It is the turbo rebuild kit you got from Kansai_sport.

Install both new journal bearing into bearing housing and c-clip it.
 C-clip the journal bearing.
Don’t forget here is an O-ring when you lock the plate and bearing housing.
Set the comp. piston ring into the thrust collar.
Most of the stock collar can be reused as well.
 Here are two pins for two holes on thrust bearing.

Remind you again…here is an O-Ring…Don’t forget it…

Lock the bearing housing and plate.
 Oil feed line side

When you wanna set the turbine wheel into the bearing system, make sure the gape of piston
ring toward bearing housing’s oil feed side. That would reduce the percentage of oil leaking.

Sometimes it is hard to push turbine shaft into bearing housing, please shake and twist the wheel
to make the piston ring on the central and then you can push the wheel into housing easily…
Make sure the thrust collar
will move smoothly…
 Make sure “A”, “B”, “C” goes back to original position as a line before you take
apart this CHRA

Now you finish the rebuild job…

Eiji Takada Dec 22, 2007 In Osaka